Dual sensor process pressure switch having high-diagnostic one-out-of-two voting architecture

ABSTRACT

A high-diagnostic, dual sensor pressure switch having a one-out-of-two voting architecture useful in commercial and industrial fluid transport systems is provided for determining whether process connections and isolation valves are plugged or closed, and whether pressure sensors are deformed, corroded or otherwise compromised. The dual pressure sensors functionally employ similar electronic technology, and are each disposed to provide variable electrical outputs to one of a plurality of discrete A/D converters. The dual pressure sensors&#39; electrical outputs are compared prior to the A/D conversion process in order to immediately identify large pressure deviations between the sensors. Each of the A/D converters&#39; digital signals are routed to one of a plurality of independent CPUs or data processors; the CPUs then generate digital output signals representing either a logical 0 (Low) or 1 (High). Each of the digital output signals are routed to one of a plurality of independent output circuits, each of which either opens or closes an associated output switch responsive to the CPUs&#39; logically evaluated output signals. Each of the plurality of output switches is connected in series with the output switches of the other output circuit(s), and the output signals are voted across the series in a one-out-of-two architecture to determine whether the device&#39;s pressure switch output circuit will either open or remain closed. In addition to routing their respective output signals to the pressure switch output circuits, the CPUs also transmit the output signals to an integrated diagnostics circuit for detection of “failed safe” conditions, and to close any circuit around an output that is determined to be failed safe.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED DEVELOPMENT

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The present invention relates generally to pressure switches useful for monitoring vital process conditions in commercial and industrial fluid transport systems, and more particularly to a high-diagnostic, dual sensor process pressure switch having a one-out-of-two voting architecture.

[0005] 2. Background of the Invention

[0006] In many commercial and industrial fluid transport systems, pressure switches are employed to measure the operational pressure of a process fluid disposed within the transport system. In particular, pressure switches are commonly used in sensitive fluid transport environments to detect hazardous process conditions, and to initiate the shut down of one or more process functions when a hazardous process condition is detected.

[0007] Generally, such pressure switches are disposed in an enclosed body that also houses an inert signal transfer medium, such as silicon, thereby effectively isolating the process fluid being measured from the pressure sensors. The housing therefore provides protection for the sensors from physical damage that could be directly caused by the process fluid. In this configuration, pressure is transmitted to the pressure sensor, via the transfer medium, through diaphragms located on the housing body that effectively separate the process fluid from the transfer medium while still permitting fluid pressures to be transmitted to the sensors.

[0008] Such pressure switches typically require verification of their operational stability at regular intervals to ensure accurate calibration and system functionality, especially in sensitive fluid transport applications. The most common calibration problems affecting presently known pressure switches are “span-shift” and “zero-shift”.

[0009] Span-shift occurs when the sensitivity of a pressure sensor is no longer accurate over an entire range of predetermined operational pressures. In contrast, zero-shift occurs when all of the pressure sensor readings are off by some constant error value within the required range. In some pressure sensors, zero-shift is much more likely to occur than span-shift; in certain other applications, span shift is more prevalent. Unfortunately, presently known pressure switches cannot generally detect either span-shift or zero-shift while a fluid transport system remains on-line. Instead, the switch must be removed from process service to validate calibration, requiring the transport system to be taken off-line, at least with respect to the particular process function being tested, and additional operation and maintenance personnel with appropriate testing equipment.

OBJECTS OF THE INVENTION

[0010] In order to overcome the aforementioned deficiencies in the prior art, it is an object of the present invention to provide a dual sensor pressure switch having a high-diagnostic, one-out-of-two voting architecture (hereinafter also referred to as “1oo2D”) capable of detecting both span-shift and zero-shift in the sensors without first removing the pressure switch from process service, and without requiring additional personnel and testing equipment. A further object of the invention is to provide a plurality of bypass switches for the dual sensor circuits that will enable maintenance personnel to calibrate the circuits without removing the pressure switch from process service. A still further object of the invention is to provide a dual sensor pressure switch wherein when one of the sensors is operationally bypassed from the transport system, the process can continue to be monitored solely by the remaining on-line sensor, and wherein the ability to open the device's switch output circuit is maintained even if one of the sensors fails entirely or is otherwise rendered ineffective.

BRIEF SUMMARY OF THE INVENTION

[0011] A high-diagnostic, dual sensor pressure switch useful for monitoring process conditions in commercial and industrial fluid transport systems is provided, the pressure switch comprising a plurality of sensor circuits, each sensor circuit further comprising a pressure sensor, an analog-to-digital (hereinafter also referred to as “A/D”) signal converter, a data processor or central processing unit, an output circuit, and an output switch; an analog signal comparator; and a diagnostics circuit further comprising an integrated diagnostics processor, a master diagnostics switch, and a plurality of servant diagnostics switches for preventing erroneous system shutdowns arising from a faulty pressure switch.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012]FIG. 1 is a schematic of a dual sensor pressure switch having a 1oo2D voting architecture according to a first embodiment of the present invention.

[0013]FIG. 2 is a schematic of a first diagnostics switch circuit and associated logic diagram according to a second embodiment of the invention.

[0014]FIG. 3 is a truth table summarizing the possible logic states for said first diagnostics switch circuit according to a third embodiment of the invention.

[0015]FIG. 4 is a schematic of a second diagnostic switch circuit and associated logic diagram according to a fourth embodiment of the invention.

[0016]FIG. 5 is a truth table summarizing the possible logic states for said second diagnostics switch circuit according to a fifth embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0017] A principal advantage of the presently disclosed 1oo2D pressure switch is that each of the dual sensors is provided with separate process connections. The configuration is designed to eliminate system down time resulting from a single closed or plugged process valve.

[0018] As seen in FIG. 1, for example, a dual sensor pressure switch having a 1oo2D voting architecture is depicted comprising a first pressure sensor 1 and a second pressure sensor 2; a sensor input comparator 3; a first A/D converter 4 and a second A/D converter 5; a first CPU 6 and a second CPU 7; an integrated diagnostics processor 8; a master diagnostics switch 8 a; a first output circuit 9 and a second output circuit 10; a first output switch 11 and a second output switch 12; a first diagnostics switch 13 and a second diagnostics switch 14; a pressure switch output circuit 15; sensor alarms and diagnostics communicators 16 and 17 for communicating alarms via DCS 18 regarding closed or plugged process valves (or taps) and sensor deformations requiring immediate operator attention; and finally, a plurality of bypass switch circuits 19 and 20 useful for allowing operators to calibrate and test the device while remaining on-line.

[0019] In practice, pressure sensors 1 and 2 output analog electrical signals that are directly compared by a sensor input comparator 3 prior to conversion to digital signals by the plurality of A/D converters 6 and 7, respectively. It is widely understood in the appropriate arts that fundamental differences between analog signals and digital signals include the fact that analog signals consist of electrical emissions measured in terms of the width of their frequency bands, whereas digital signals are machine-level binary strings measured in terms of bits per second (bps).

[0020] Direct comparison of the analog signals by sensor input comparator 3 enables prompt detection of significant deviations between the pressure readings of sensors 1 and 2 in excess of a particular pressure range, each sensor having been pre-assigned a pressure range considered within its acceptable operating parameters.

[0021] If the deviations in pressure readings from sensors 1 and 2 exceed the acceptable range, then sensor input comparator 3 immediately outputs a signal to sensor alarms and diagnostics communicators 16 and 17, such that an operator (or a monitoring CPU or data processor) quickly becomes aware of the problem so that further action can be initiated to preserve the operational integrity of the process system via DCS 18. The sensor alarms may communicate diagnostics information regarding, for example, a particular process valve (or tap) that is either closed or plugged, or that one (or both) of the pressure sensors has become deformed due to heat or fatigue, etc.

[0022] Provided that no alarm warranting immediate shut-down of the process system is initiated by the sensor alarms and diagnostics communicators 16 and 17 (for example, in the unusual event both sensors are simultaneously found to be defective), the plurality of A/D converters 4 and 5 will output their respective converted digital signals to said plurality of associated CPUs 6 and 7. In other words, the converted digital signals created by A/D converter 4 are output directly to CPU 6, and the converted digital signals created by A/D converter 5 are output directly to CPU 7, for signal normalization and further routing within the pressure switch circuit.

[0023] At this point, the normalized digital signals output from CPUs 6 and 7 are routed directly to integrated diagnostics processor 8 before further transmission to each of output circuits 9 and 10, respectively, via master diagnostics switch 8 a. According to one aspect of the invention, integrated diagnostics processor 8 and master diagnostics switch 8 a may be either separate but integrated system components, or instead formed structurally integral for simplicity of operation.

[0024] Output circuits 9 and 10 are designed such that their respective output signals are passed to integrated diagnostics processor 8 prior to the opening of either of output switches 11 and 12. The resulting delay allows both of diagnostics switches 13 and 14 to close before either of output switches 11 or 12 are erroneously opened. Diagnostic switches 13 and 14 will only reopen responsive to a signal output from master diagnostics switch 8 a, the particular signal being determined based on the logic shown in the diagrams presented in FIGS. 2 and 4, and as described in the truth tables provided in FIGS. 3 and 5. The device's essential circuitry and associated logic are next described with further reference to the mentioned figures.

[0025] First, and referring still to FIG. 1, the presently disclosed device comprises at least two discrete sensor circuits. In the depicted embodiment, the first sensor circuit comprises a pressure sensor 1, an A/D converter 4, a CPU 6, an output circuit 9, and an output switch 11.

[0026] In practice, pressure sensor 1 sends an analog electrical signal to A/D converter 4, where the analog signal is converted to digital. The converted digital signal is then output directly to CPU 6, which generates a logical output signal of either 0 or 1 based on an adjustable, predetermined set point. CPU 6 then sends the logical output signal to output circuit 9. Output circuit 9 receives the digital signal output from CPU 6, and opens output switch 11 only when the input logical signal is a 0. Output switch 11 remains closed when the logical input is a 1.

[0027] Sensor circuit 2 (also shown in FIG. 1) is constructed similarly, and comprises pressure sensor 2, A/D converter 5, CPU 7, output circuit 10 and output switch 12. Pressure sensor 2 sends an analog electrical signal to A/D converter 5, where the analog signal is converted to digital. The converted digital signal is then output to CPU 7, which generates a logical output of either 0 or 1 based on its adjustable, predetermined set point. CPU 7 then sends the logical output signal to output circuit 10. Output circuit 10 receives the output signal from CPU 7, and opens output switch 12 only when the logical signal input is a 0. Output switch 12 remains closed when the logical input is a 1.

[0028] The disclosed dual sensor pressure switch also includes an integrated diagnostics circuit comprising at least an integrated diagnostics processor 8 and master diagnostics switch 8 a (see FIG. 1), and a plurality of responsive diagnostics switch circuits. The logic elements associated with the operation of each of the diagnostics switches are depicted in FIGS. 2 and 4, and are discussed in greater detail immediately below.

[0029] Referring to FIG. 2, the logic protocol of diagnostics switch circuit 28 is shown comprising a logical signal input from said first CPU 21, a signal input from said first output circuit 22, a signal input from said second CPU 24, and a signal input from said second output circuit 25. Both of the logical output signals from said first CPU and said first output circuit are transmitted to integrated diagnostics processor 8 where they are input to NAND gate logic 23. The NAND gate logic evaluates the collective input signals and outputs a responsive logical output of either 0 or 1. A logical 0 is output from the NAND gate logic when the evaluated input signals match, and a logical 1 is output when the evaluated input signals do not match.

[0030] Similarly, each of the logical output signals from said second CPU and said second output circuit are transmitted to integrated diagnostics processor 8, where they are input to AND gate logic 26. The AND gate logic evaluates the collective input signals and outputs a responsive logical output of either 0 or 1. A logical 0 is output from the AND gate logic when the evaluated input signals do not match, and a logical 1 is output when the evaluated input signals match.

[0031] The resulting logical outputs from the NAND gate logic and the AND gate logic are then output to further AND gate logic 27. This gate evaluates its collective input and promulgates a final logical output signal of either 0 or 1 for transmission to first diagnostics switch circuit 28. A logical 0 is output from the AND gate when the input signals do not match, and a logical 1 is output when the compared input signals are the same. Said first diagnostics switch circuit 28 receives the final logical output generated by AND gate 27 via diagnostics master switch 8 a, and will open when the received logical input signal is a 0. Conversely, first diagnostics switch 28 will close when the received logical input signal is a 1. A truth table summarizing the possible logical states of first diagnostics switch 28 is provided in FIG. 3.

[0032] The logical protocol for said second diagnostics switch 48 is set forth in FIG. 4, and comprises a logical signal input from said second CPU 41, a signal input from said second output circuit 42, a signal input from said first CPU 44, and a signal input from said first output circuit 45. Both of the logical output signals from said second CPU and said second output circuit are transmitted to integrated diagnostics processor 8 where they are input to NAND gate logic 43. The NAND gate evaluates the collective input signals and outputs a responsive logical output of either 0 or 1. A logical 0 is output from the NAND gate logic when the evaluated input signals match, and a logical 1 is output when the evaluated input signals do not match.

[0033] Similarly, each of the logical output signals from said first CPU and said first output circuit are transmitted to integrated diagnostics processor 8, where they are input to AND gate logic 46. The AND gate evaluates the collective input signals and outputs a responsive logical output of either 0 or 1. A logical 0 is output from the AND gate logic when the evaluated input signals do not match, and a logical 1 is output when the evaluated input signals are the same.

[0034] The resulting logical outputs from the NAND gate logic and the AND gate logic are then output to further AND gate logic 47. This gate evaluates its collective input and promulgates a final logical output signal of either 0 or 1 for transmission to second diagnostics switch circuit 48. A logical 0 is output from the AND gate when the input signals do not match, and a logical 1 is output when the compared input signals are the same. Second diagnostics switch circuit 48 receives the final logical output generated by AND gate 47 via diagnostics master switch 8 a, and will open when the received logical input signal is a 0. Conversely, second diagnostics switch 48 will close when the received logical input signal is a 1. A truth table summarizing the possible logical states of second diagnostics switch 48 is provided in FIG. 5.

[0035] The foregoing specification is provided for illustrative purposes only, and is not intended to describe all possible aspects of the present invention. Moreover, while the invention has been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the pertinent arts will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from either the spirit or scope thereof. Having herein described the general nature and characteristics of the invention, what is claimed is: 

1. A pressure switch for monitoring process conditions in a fluid transport system, said pressure switch comprising: a plurality of sensor circuits; an analog signal comparator; an integrated diagnostics circuit; and a pressure switch output circuit.
 2. The pressure switch of claim 1 further comprising a plurality of bypass switch circuits, wherein said plurality of bypass switch circuits enable an operator to perform maintenance on said pressure switch while the pressure switch remains on-line in the fluid transport system.
 3. The pressure switch of claim 1, wherein each of said plurality of sensor circuits further comprises a pressure sensor; an analog-to-digital signal converter; a central processing unit; a pressure sensor output circuit; and a pressure sensor output switch.
 4. The pressure switch of claim 1, wherein said analog signal comparator directly compares a plurality of analog input signals received from a plurality of pressure sensors, and wherein information regarding differences between the signals generated by each of said pressure sensors may be output directly to a sensor alarm.
 5. The pressure switch of claim 4, wherein when said analog signal comparator detects the presence of particular predetermined differences between the signals generated by said plurality of pressure sensors, said sensor alarm is capable of communicating information to an operator regarding whether a particular system component is either closed or plugged.
 6. The pressure switch of claim 4, wherein when said analog signal comparator detects the presence of particular predetermined differences between the signals generated by said plurality of pressure sensors, said sensor alarm communicates information to an operator regarding whether any of said pressure sensors is operationally defective.
 7. The pressure switch of claim 1 wherein said integrated diagnostics circuit further comprises an integrated diagnostics processor; a master diagnostics switch; and a plurality of servant diagnostics switches responsive to a plurality of switch control signals generated by said master diagnostics switch.
 8. The pressure switch of claim 7 wherein said integrated diagnostics processor and said master diagnostics switch are formed structurally integral.
 9. The pressure switch of claim 7 wherein said integrated diagnostics processor and said master diagnostics switch are not formed structurally integral.
 10. The pressure switch of claim 7 wherein said master diagnostics switch outputs a switch control signal to each of said plurality of said servant diagnostics switches, and wherein said switch control signal is responsive to a diagnostics control signal generated by said integrated diagnostics processor.
 11. The pressure switch of claim 10 wherein said diagnostics control signal generated by said integrated diagnostics processor may also be output to a diagnostics communicator for relay to an operator.
 12. The pressure switch of claim 11 wherein said diagnostics communicator is capable of communicating information to an operator regarding pressure sensor deviations, bypass state indicators, and whether any of said servant diagnostic switches are closed.
 13. A pressure switch for monitoring process conditions in a fluid transport system, said pressure switch comprising: a plurality of sensor circuits, wherein each of said sensor circuits further comprises a pressure sensor, an analog-to-digital signal converter, a central processing unit, a pressure sensor output circuit, and a pressure sensor output switch; an analog signal comparator, wherein said analog signal comparator compares a plurality of analog electrical signals input directly from a plurality of pressure sensors for determining whether a particular component within the fluid transport system is closed or plugged, and whether any of said pressure sensors is operationally defective, and wherein said determination is communicated to an operator via a communicator; an integrated diagnostics circuit, wherein said integrated diagnostics circuit further comprises an integrated diagnostics processor, a master diagnostics switch responsive to a diagnostics control signal transmitted from said integrated diagnostics processor, and a plurality of servant diagnostics switches responsive to a plurality of switch control signals transmitted from said master diagnostics switch, and wherein said integrated diagnostics circuit is capable of communicating information to a diagnostics communicator regarding pressure sensor deviations, bypass state indicators, and diagnostics switch states to an operator of the fluid transport system; a plurality of bypass switch circuits which enable an operator to perform maintenance on said pressure switch while the pressure switch remains on-line in the transport system; and a pressure switch output circuit responsive to a plurality of diagnostics switch control signals generated by said plurality of servant diagnostics switches. 